Method and apparatus for coil-less magnetoelectric magnetic flux switching for permanent magnets

ABSTRACT

Methods and apparatus that employ a coil-less magnetoelectric flux switch arrangement to repeatedly switch magnetic flux from at least one permanent magnet for the purposes of generating motive force and/or electrical energy.

This application is a continuation of application Ser. No. 11/279,162,filed Apr. 10, 2006, which is a continuation of application Ser. No.11/229,079, filed Sep. 16, 2005, now U.S. Pat. No. 7,030,724, issuedApr. 18, 2006, which is a continuation of application Ser. No.10/862,776, filed Jun. 7, 2004, now U.S. Pat. No. 6,946,938 issued Sep.20, 2005, all of which are herein incorporated by reference.

FIELD OF THE INVENTION

The present invention relates generally to magnetic fields frompermanent magnets and the control of such magnetic fields for use inmotors, generators and the like. More particularly, the presentinvention relates to methods and apparatus that employ a coil-lessmagnetoelectric (ME) magnetic flux switching construct to repeatedlyswitch magnetic flux from at least one permanent magnet for the purposesof generating motive force and/or electrical energy.

BACKGROUND OF THE INVENTION

The basic electro-mechanical processes involved in motors and generatorsare well-known. Mechanical power is produced (in the case of a motor) orelectrical energy is generated (in the case of a generator) by theinteraction of the electro-magnetic forces between the rotor and stator.While almost all conventional motors utilize electromagnetic forcesproduced by running current through a series of windings in the form ofcoils of wire to generate the electro-magnetic field that turns therotor, the design of motors powered by magnetic fields from permanentmagnets date back to as early as the 1840's. For numerous reasons, suchpermanent magnet powered motors have not been practical or competitivewhen compared to conventional electrical motors powered byelectro-magnetic fields. For general background information on permanentmagnets and permanent magnet motor design, reference is made toMoskowitz, Permanent Magnet Design and Application Handbook (1976),Hanselman, Brushless Permanent Magnet Motor Design (2003), and Gieras etal., Permanent Magnet Motor Technology Revised (2003).

Recently a permanent magnet powered motor construct has been proposedthat overcomes many of the challenges long associated with permanentmagnet motors. U.S. Pat. Nos. 6,246,561 and 6,342,746 issued to Flynndescribe methods for controlling the path of magnetic flux from apermanent magnet and devices incorporating the same. In these patents, apermanent magnet device includes a permanent magnet having north andsouth pole faces with a first pole piece positioned adjacent one poleface thereof and a second pole piece positioned adjacent the other poleface thereof so as to create at least two potential magnetic flux paths.A first control coil is positioned along one flux path and a secondcontrol coil is positioned along the other flux path, each coil beingconnected to a control circuit for controlling the energization thereof.The control coils may be energized in a variety of ways to achieveddesirable motive and static devices, including linear reciprocatingdevices, linear motion devices, rotary motion devices and powerconversion.

It has long been known that certain materials commonly referred to asliquid crystals can be oriented by a magnetic field. As early as 1894,Curie stated that it would be possible for an asymmetric molecular bodyto polarize in one direction under the influence of a magnetic field.The practical application of this effect is most commonly seen inmagnetically ordered crystals even in conditions of symmetry of themolecules of the crystal. U.S. Pat. No. 4,806,858, for example,describes an inspection technique for magnetization that utilizes liquidcrystal material to determine whether a sample has been appropriatelymagnetized. The use of a liquid crystal layer to change the magneticflux resistance of a single magnetic path was described in JapaneseAbstract No. 621 17757A2 (1985).

More recently, the magnetoelectric effects of liquid crystal materialsin the form of magnetorestrictive and piezoelectric materials have beenthe subject of renewed research and development. Generally referred toas magnetoelectric (ME) materials, the research and development intovarious properties of these ME materials are described, for example, inRyu et al, “Magnetoelectric Effect in Composites of Magnetorestrictiveand Piezoelectric Materials,” Journal of Electroceramics, Vol. 8,107-119 (2002), Filipov et al, “Magnetoelectric Effects atPiezoresonance in Ferromagentic-Ferroelectric Layered Composites,”Abstract, American Physical Society Meeting (March 2003) and Chang etal., “Magneto-band of Stacked Nanographite Ribbons,” Abstract, AmericanPhysical Society Meeting (March 2003).

While many of the properties of ME materials are understood and thereare numerous applications for the use of such liquid crystal materials,there is nothing which suggests how to make effective use of MEmaterials in the context of the design of permanent magnet motors andthe like.

SUMMARY OF THE INVENTION

The present invention employs a coil-less magnetoelectric (ME) magneticflux switching construct to repeatedly switch magnetic flux from atleast one permanent magnet for the purposes of generating motive forceand/or electrical energy. In one embodiment, a pair of permanent magnetsare similarly oriented with each pole operably adjacent an associatedfirst and second magnetic flux conductor.

A first pair of coil-less ME magnetic flux switches are positionedbetween a corresponding first end of the first and second magnetic fluxconductors and a third magnetic flux conductor. A second pair ofcoil-less ME magnetic flux switches are positioned between acorresponding second end of the first and second magnetic fluxconductors and a fourth magnetic flux conductor. The first and secondpairs of coil-less ME magnetic flux switches are repeatedly, alternatelyenabled to permit magnetic flux from the permanent magnets to cyclicallyflow through the third magnetic flux conductor and then the fourthmagnetic flux conductor. Preferably, the coil-less ME magnetic fluxswitches are comprised of a laminate magnetoelectric (ME) materialcontrolled by applying a voltage across the material to switch themagnetic conductivity of the ME material.

In one rotary motor embodiment of the present invention, the third andfourth magnetic flux conductors are different regions of a single rotor.The first and second magnetic flux conductors along with the permanentmagnets serve as the stator. By continuous switching of the magneticflux using the pair of coil-less ME magnetic flux switches, rotationalmotive force is applied to the rotor and a rotary motor is created.

In another rotary motor embodiment of the present invention, the rotoris provided with the permanent magnets and the coil-less ME magneticflux switches and the stator is the common element that provides thedifferent regions for the third and fourth magnetic flux conductors. Inone version of this embodiment, the rotor may be the rotating element ofthe motor. In another version of this embodiment, the stator may be therotating element of the motor.

In one rotary motor/generator embodiment of the present invention, oneor more pickup coils are wound around at least one of the magnetic fluxconductors of the stator element of a rotary motor. Unlike the motorconstruct of U.S. Pat. Nos. 6,246,561 and 6,342,746, current is notapplied to any of these coils. Instead, the coils are used as the pickupcoils of an alternating current generator. In an alternate embodiment ofthis invention, a current may be applied to the coils to utilizes thesecoils as control coils to enhance or supplement the magnetic fluxswitching effected by the coil-less ME magnetic flux switches asdescribed by the present invention, or to provide additional operationalbenefits to the magnetic flux switching constructs as described in thisinvention and/or U.S. Pat. Nos. 6,246,561 and 6,342,746.

In one solid state generator embodiment of the present invention, apickup coil is wound around at least one of the first and secondmagnetic flux conductors of a given solid state flux switchingconstruct. In one version of this solid state generator embodiment, atleast one of the first and second magnetic flux conductors having apickup coils is shared by two or more solid state flux switchingconstructs. In another version of this solid state generator embodiment,a pickup coil is wound around at one of the third and fourth magneticflux conductors of a given solid state flux switching construct and atleast one of the third and fourth magnetic flux conductors are shared bytwo or more solid state flux switching constructs.

In another embodiment of a solid state generator in accordance with thepresent invention, a permanent magnet is at least partially coaxiallysurrounded by at least one coil-less ME magnetic flux switch with atleast one coil positioned outside the coil-less magnetic flux switch. Ina first version of this embodiment, the coil is wrapped coaxially withthe permanent magnet and the coil-less magnetic flux switch. In a secondversion of this embodiment, the coil is positioned transverse to alongitudinal axis of the permanent magnet. In a third version of thisembodiment, the coil is wrapped as one or more torroids positionedaround the permanent magnet.

In another embodiment, at least one permanent magnet has each poleoperably adjacent an associated first and second magnetic fluxconductor. The first and second magnetic flux conductors each include apair of selectively enabled permanent magnets with opposite poleorientations. Each permanent magnet in the first and second magneticflux conductor is selectively enabled in this embodiment by acorresponding pair of coilless magnetic flux switches interposed betweenthe poles of each of these magnets and the corresponding adjacentportions of the first and second magnetic flux conductors. In oneversion of this embodiment, the pair of magnets in the first and secondmagnetic flux conductors can be separated with a magnetic insulatormaterial such as MU metal. In another embodiment, a third and fourthmagnetic flux conductor can be added to the corresponding end of thefirst and second magnetic flux conductors with an additional set ofinterposed coil-less magnetic flux switches arranged as described in thepreferred embodiment.

In a linear motor/actuator embodiment in accordance with the presentinvention, the third and fourth magnetic flux conductors are effectivelyrails along which a shuttle is moved between carrying the permanentmagnets, the first and second magnetic flux conductors and the coil-lessME magnetic switches.

In a preferred embodiment, the coil-less ME magnetic flux switches areimplemented as a liquid crystal ME material that is electronicallycontrollable. In an alternate embodiment, the ME material may bephysically or optically controllable. Preferably, the ME material isprocessed onto a desired surface of the magnetic flux conductor orpermanent magnet by thin film deposition, sputtering, or other thin filmprocessing techniques. Alternatively, the ME material may be positionedphysically interposed between the desired surfaces of the magnetic fluxconductors or permanent magnets. In one embodiment, an index matchingcoating material may be interposed between the ME material and thedesired surface of the magnetic flux conductors or permanent magnets toimprove the magnetic flux characteristics of the completed construct. Inanother embodiment, a magnetic insulator material, such as MU metal canbe used to house an entire magnetic flux switching construct to preventexternal magnetic fields or may be used to magnetically isolate selectedportions of a magnetic flux switching construct.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1 and 2 are schematic diagrams of a preferred embodiment ofmagnetic flux switching construct in accordance with the presentinvention.

FIG. 3 is a schematic diagram of one embodiment of a motor/generator inaccordance with the present invention.

FIG. 4 is a schematic diagram of an alternate embodiment of a rotarymotor in accordance with the present invention.

FIG. 5 is a schematic diagram of an alternative embodiment of a magneticflux switching construct in accordance with the present invention.

FIGS. 6 and 7 are schematic diagrams of alternate embodiments of amotor/generator in accordance with the present invention.

FIGS. 8, 9 and 10 are schematic diagrams of alternative embodiments of amagnetic flux switching construct in accordance with the presentinvention.

FIG. 11 is a top plan view of a coaxial construction of a generator inaccordance with the present invention.

FIG. 12 is a side view of the embodiment shown in FIG. 11.

FIG. 13 is a side view of an alternate embodiment of a coaxialconstruction of a generator in accordance with the present invention.

FIG. 14 is a side view of an embodiment of a coaxial construction of agenerator in accordance with the present invention.

FIGS. 15 and 16 are schematic views of alternate embodiments of multipleflux switching constructs in accordance with one embodiment of thepresent invention.

FIG. 17 is a schematic diagram of an alternate embodiment of a linearmotor/actuator in accordance with the present invention.

DETAILED DESCRIPTION OF THE DRAWINGS

Referring to FIGS. 1 and 2, a first embodiment of the of a magnetic fluxswitching construct 100 in accordance with the present invention will bedescribed. A pair of permanent magnets 102, 104 are similarly orientedwith each north pole (N) operably adjacent a first magnetic fluxconductor 112 and each south pole (S) operably adjacent a secondmagnetic flux conductor 114. Preferably, the permanent magnets 102, 104are high strength ceramic or rare-earth permanent magnets such asneodidium, although any material capable of being magnetized andretaining that magnetization for a period of time sufficient for theintended use of the construct 100 could be used. Preferably, themagnetic flux conductors 112, 114 are low loss magnetic flux laminatematerials, such as hyperco or an MD grade metal, although any iron,steel or ferrous alloy could be used provided that the magnetic fluxloss of such material is within the design parameters of the strength ofmagnetic flux to be switched by the construct 100.

A first pair of coil-less magnetoelectric (ME) magnetic flux switches142, 144 are sandwiched between a corresponding first end of the firstand second magnetic flux conductors 112, 114 and a third magnetic fluxconductor 122. A second pair of coil-less ME magnetic flux switches 152,154 are positioned between a corresponding second end of the first andsecond magnetic flu conductors 112, 114 and a fourth magnetic fluxconductor 124. Preferably, each of the first and second pairs ofcoil-less ME magnetic flux switches 142, 144, 152, 154 are repeatedly,alternately enabled by an electronic control circuit 150 (shown forconvenience as connected to just one switch). Preferably, the coil-lessME magnetic flux switches 142, 144, 152, 154 are comprised of a laminatemagnetoelectric (ME) material such as the ME materials described in Ryuet al, “Magnetoelectric Effect in Composites of Magnetorestrictive andPiezoelectric Materials,” Journal of Electrocerarnics, Vol. 8, 107-119(2002). Alternatively, the ME materials may be any ME or liquid crystalmaterial.

As shown in FIG. 1, the switching of the first pair of coil-less MEmagnetic flux switches 142 and 144 into an “on” position and the secondpair of coil-less ME magnetic flux switches 152 and 154 into the “offposition permits magnetic flux as shown at 132, 134 from the permanentmagnets 102, 104 to flow through the third magnetic flux conductor 122and not the fourth magnetic flux conductor 124. Switching of the firstpair of coil-less ME magnetic flux switches 142 and 144 into an “offposition and the second pair of coil-less ME magnetic flux switches 152and 154 into the “on” position then permits magnetic flux as shown at136, 138 from the permanent magnets 102, 104 to flow through the fourthmagnetic flux conductor 124 and not the third magnetic conductor 122.

As this switching process is cyclically repeated under control ofcontrol circuit 150, the switching of the magnetic flux between thepositions at 132, 134 and the positions at 136, 138 is accomplished. Aswill be described, there are numerous applications for this switchingconstruct 100. In the case of the embodiment shown in FIGS. 1 and 2, apair of pickup coils 162, 164 are wound around the first and secondmagnetic flux conductors 112, 114, respectively. Electricity isgenerated at these pickup coils by virtue of the switching magneticflux. It will be seen that an AC output signal is generated at theterminals of the pickup coils with a frequency that is dependent uponthe speed at which the switching process is cycled. The frequency islimited by the switching speeds of the specifications of the particularcoil-less ME magnetic flux switches utilized. In a preferred embodimentof a laminate coil-less ME magnetic flux switch, switching frequenciesmay be up to 100 GHz. It will be apparent that numerous rectification,power conditioning and other signal processing techniques can be used tomodify the output of the pickup coils 162, 164. In one embodiment, atleast a portion of the output of the pickup coils 162, 164 is used topower the control circuit 150.

Referring now to FIG. 3, the use of the magnetic flux switchingconstruct of the present invention in a rotary motor application will bedescribed. In general, the arrangement of components in this embodimentis similar to the rotary motors as described in U.S. Pat. Nos. 6,246,561and 6,342,746, except that no control coils are used to controlswitching of the magnetic flux. The rotary motor 200 includes componentsthat are similar to those used in the magnetic flux switching construct100 except that the third magnetic flux conductor 122 and fourthmagnetic flux conductor 124 are different regions of a single rotorelement 202. Preferably, the rotor element 202 includes a number ofnotches 210 that are dimensioned to permit the selectively coupling ofthe magnetic flux through the enabled pair of switches 142, 144 or 152,154 in a timed manner to generate an effective rotating force in onerotational direction. The first and second magnetic flux conductors 112,114 are curved and along with the permanent magnets 102, 104 serve asthe stator 204 of the rotary motor 200. By continuous switching of themagnetic flux using the pair of coil-less ME magnetic flux switches 142,144 and 152, 154, rotational motive force is applied to the rotor 202.It will be seen that a rotary motor 200 having any even number of polescould be constructed, such as a six pole motor or a twelve pole motor,for example. For a detailed understanding of the timing and constructionof a control circuit that would enable the switches 142, 144, 152, 154,reference is made to U.S. Pat. Nos. 6,246,561 and 6,342,746.

In another embodiment of a rotary motor 220 as shown in FIG. 4, therotor 222 is provided with the permanent magnets and the coil-less MEmagnetic flux switches 142, 144, 152, 154 and the stator 224 is thecommon element that provides the different regions for the third andfourth magnetic flux conductors 122, 124. In one version of thisembodiment, the rotor 222 may be the rotating element of the motor 220.In another version of this embodiment, the stator 224 may be therotating element of the motor 220. In one embodiment, the controlcircuit 150 can be carried by the rotor 222 and may be powered by abattery or by a shaft feed powered by pickup coils or an outside source.

In one rotary motor/generator embodiment as shown in FIG. 3, one or morepickup coils 162, 164 are wound around at least one of the first andsecond magnetic flux conductors 112, 1 14 of the stator 204 of rotarymotor 200.

In another embodiment as shown in FIGS. 5-7, at least one permanentmagnet has each pole operably adjacent an associated first and secondmagnetic flux conductor. In one embodiment, the first and secondmagnetic flux conductors each include a pair of selectively enabledpermanent magnets with opposite pole orientations. Each permanent magnetin the first and second magnetic flux conductor is selectively enabledin this embodiment by a corresponding pair of coil-less magnetic fluxswitches interposed between the poles of each of these magnets and thecorresponding adjacent portions of the first and second magnetic fluxconductors. In one version of this embodiment, the pair of magnets inthe first and second magnetic flu conductors can be separated with amagnetic insulator material such as MU metal. In another embodiment, athird and fourth magnetic flux conductor can be added to thecorresponding end of the first and second magnetic flux conductors withan additional set of interposed coil-less magnetic flux switchesarranged as described in the preferred embodiment. This construct can beused to create a rotary motor/generator as shown in FIGS. 6-7, with anynumber of pickup coils.

In another embodiment as shown in FIG. 8, a single permanent magnet isused to provide magnetic flux for the magnetic flux switching constructand multiple pick up coils are arranged on each of the first and secondmagnetic flux conductors.

In another embodiment as shown in FIG. 9, a pair of permanent magnetsare used to selectively provide magnetic flux with a second set ofcoil-less ME magnetic flux switches interposed in between the poles ofeach of the permanent magnets and the first and second magnetic fluxconductors. This second set of coil-less ME magnetic flux switches maybe controlled by the control circuit for the first set of coil-less MEmagnetic flux switches that selectively flux connect the third andfourth magnetic flux conductors or may be controlled by a separatecontrol circuit. FIG. 10 is an alternate embodiment of the embodimentshown in FIG. 9 with a pair of paired and coil-less ME magnetic fluxswitched set of permanent magnets used to generate magnetic flux for thepresent invention.

In another embodiment of a solid state generator as shown in FIGS.11-14, a permanent magnet is at least partially coaxially surrounded byat least one coil-less ME magnetic flux switch with at least one coilpositioned outside the coil-less magnetic flux switch. In a firstversion of this embodiment as shown in FIGS. 11 and 12, the coil iswrapped coaxially with the permanent magnet and the coil-less magneticflux switch. In a second version of this embodiment as shown in FIG. 13,the coil is positioned transverse to a longitudinal axis of thepermanent magnet. In a third version of this embodiment as shown in FIG.14, the coil is wrapped as one or more torroids positioned around thepermanent magnet.

In a solid state generator embodiment of the present invention as shownin FIGS. 15, a pickup coil is wound around at least one of the first andsecond magnetic flux conductors of a given solid state flux switchingconstruct. In this embodiment, at least one of the first and secondmagnetic flux conductors having a pickup coil is shared by two or moresolid state flux switching constructs. In another version of this solidstate generator embodiment as shown in FIG. 16, a pickup coil is woundaround at one of the third and fourth magnetic flux conductors of agiven solid state flux switching construct and at least one of the thirdand fourth magnetic flux conductors are shared by two or more solidstate flux switching constructs.

In a linear motor/actuator embodiment in accordance with the presentinvention as shown in FIG. 17, the third and fourth magnetic fluxconductors are effectively rails along which a shuttle is moved betweencarrying the permanent magnets, the first and second magnetic fluxconductors and the coil-less ME magnetic switches. The rails may be tiedtogether as part of a common superstructure. One or more sets of themagnetic flux switching construct may be incorporated into the shuttleportion of this embodiment.

It will be apparent that numerous combinations of the variousembodiments of the present invention may be arranged in differentcombinations to take advantage of different aspects of the presentinvention.

The complete disclosures of the patents, patent applications andpublications cited herein are incorporated by reference in theirentirety as if each were individual incorporated. Various modificationsand alterations to this invention will become apparent to those skilledin the art without departing from the scope or spirit of this invention.

1. An apparatus for switching magnetic flux comprising: a permanentmagnet having a north pole and a south pole; at least two magnetic fluxconductors operably connected to define different magnetic paths betweenthe north pole and the south of the permanent magnet; for each magneticpath, at least one coil-less magnetoelectric flux switch operablypositioned along the magnetic path; and a control system operablyconnected to the magnetoelectric flux switches to selectively switch aflow of magnetic flux from the permanent magnet through the differentmagnetic paths.
 2. The apparatus of claim 1 wherein the control systemselectively controls at least one magnetic property of themagnetoelectric flux switches by electronic control, optical control,mechanical control, or any combination thereof applied to themagnetoelectric flux switch.
 3. The apparatus of claim 1 furthercomprising a pickup coil wound around at least one of the magnetic fluxconductors such that a flow of current is generated in the pickup coilby alternately switching the flow of magnetic flux through the at leastone of the magnetic flux conductors.
 4. The apparatus of claim 1 whereinthe coil-less magnetoelectric flux switches are comprised of liquidcrystal magnetoelectric material.
 5. The apparatus of claim 4 whereinthe coil-less magnetoelectric flux switches are comprised of laminatedlayers of liquid crystal magnetoelectric material:
 6. A method forswitching magnetic flux generated by a permanent magnet having a northpole and a south pole, the method comprising: operably connecting atleast two magnetic flux conductors to define different magnetic pathsbetween the north pole and the south of the permanent magnet; for eachmagnetic path, operably positioning at least one coil-lessmagnetoelectric flux switch along the magnetic path; and controlling thecoil-less magnetoelectric flux switch to selectively switch a flow ofmagnetic flux from the permanent magnet through the different magneticpaths.
 7. The method of claim 6 wherein the step of controlling isperformed by electronic control, optical control, mechanical control, orany combination thereof applied to the magnetoelectric flux switch.
 8. Amethod for generating a flow of current in a pickup coil associated withswitching of magnetic flux generated by a permanent magnet having anorth pole and a south pole, the method comprising: operably connectingat least two magnetic flux conductors to define different magnetic pathsbetween the north pole and the south of the permanent magnet; for eachmagnetic path, operably positioning at least one coil-lessmagnetoelectric flux switch along the magnetic path; providing at leastone pickup coil wound around at least one of the magnetic fluxconductors; and controlling the coil-less magnetoelectric flux switch toselectively switch a flow of magnetic flux from the permanent magnetthrough the different magnetic paths such that a flow of current isgenerated in the pickup coil by alternately switching the flow ofmagnetic flux through the at least one of the magnetic flux conductors.9. The apparatus of claim 8 wherein the step of controlling is performedby electronic control, optical control, mechanical control, or anycombination thereof applied to the magnetoelectric flux switch.